Fibre based panels with a decorative wear resistance surface

ABSTRACT

A method to produce building panels is disclosed which method includes the step of applying a layer ( 5 ) comprising a mix of fibers ( 14 ), binder ( 12 ), and wear resistant particles ( 12 ) on a carrier ( 6 ), pressing the layer ( 5 ) with an embossed matrix ( 2   a,    2   b ) and providing embossed portions ( 4 ) and filling the embossed portions with decorative a substance ( 3 ).

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of U.S. ProvisionalApplication No. 61/295,514, filed on Jan. 15, 2010, and claims thebenefit of Swedish Application No. 1050039-5, filed on Jan. 15, 2010.The entire contents of each of U.S. Provisional Application No.61/295,514 and Swedish Application No. 1050039-5 are hereby incorporatedherein by reference.

TECHNICAL FIELD

The disclosure generally relates to the field of fibre-based panels withwear resistant surfaces for building panels, preferably floor panels.The disclosure relates to building panels with such wear resistancesurface and particularly to production methods to produce such panels.

FIELD OF APPLICATION

The present disclosure is particularly suitable for use in floatingfloors, which are formed of floor panels comprising a core and adecorative wear resistant solid surface layer comprising fibres, bindersand wear resistant particles as described in WO 2009/065769. Thefollowing description of technique, problems of known systems andobjects and features of the invention will therefore, as anon-restrictive example, be aimed above all at this field of applicationand in particular at floorings which are similar to traditional floatingwood fibre based laminate floorings. The disclosure does not excludefloors that are glued down to a sub floor.

It should be emphasized that the disclosure can be used to produce acomplete panel or a separate surface layer, which is for example appliedto a core in order to form a panel. The disclosure can also be used inapplications as for example wall panels, ceilings, and furniturecomponents and similar.

BACKGROUND

Wood fibre based direct pressed laminated flooring usually comprises acore of a 6-12 mm fibre board, a 0.2 mm thick upper decorative surfacelayer of laminate and a 0.1-0.2 mm thick lower balancing layer oflaminate, plastic, paper or like material.

The surface layer of a laminate floor is characterized in that thedecorative and wear properties are generally obtained with two separatelayers one over the other.

The printed decorative paper and the overlay are impregnated withmelamine resin and laminated to a wood fibre based core under heat andpressure.

Recently new “paper free” floor types have been developed with solidsurfaces comprising a substantially homogenous mix of fibres, bindersand wear resistant particles.

The wear resistant particles are preferably aluminium oxide particles,the binders are preferably thermosetting resins such as amino resins andthe fibres are preferably wood based. Other suitable wear resistantmaterials are for example silica or silicon carbide. In mostapplications decorative particles such as for example colour pigmentsare included in the homogenous mix. In general all these materials arepreferably applied in dry form as a mixed powder on a HDF core and curedunder heat and pressure to a 0.1-1.0 mm solid layer.

Several advantages over known technology and especially overconventional laminate floorings can be obtained:

-   -   The wear resistant surface layer, which is a homogonous mix, can        be made much thicker and a wear resistance is achieved, which is        considerably higher.    -   New and very advanced decorative effects can be obtained with        deep embossing and by separate decorative materials, which can        be incorporated into the homogenous surface layer and        coordinated with the embossing.    -   An increased impact resistance can be reached with a homogenous        surface layer, which is thicker and has a higher density.    -   The homogenous surface layer can comprise particles that have a        positive impact on sound and moisture properties.    -   Production costs can be reduced since low cost and even recycled        materials can be used and several production steps can be        eliminated.

Powder technology is very suitable to produce a decorative surfacelayer, which is a copy of stone and ceramics. It is however moredifficult to create designs such as for example wood decors.

Powder based floors could reach a much higher market share if advanceddesigns similar to for example wood floorings could be made in a costefficient way as described in this application.

DEFINITION OF SOME TERMS

In the following text, the visible surface of the installed floor panelis called “front side”, while the opposite side of the floor panel,facing the sub floor, is called “rear side”. By “surface layer” aremeant all layers which give the panel its decorative properties and itswear resistance and which are applied to the core closest to the frontside covering preferably the entire front side of the floorboard. By“decorative surface layer” is meant a layer, which is mainly intended togive the floor its decorative appearance. “Wear layer” relates to alayer, which is mainly adapted to improve the durability of the frontside.

By “horizontal plane” is meant a plane, which extends parallel to theouter part of the surface layer. By “horizontally” is meant parallel tothe horizontal plane and by “vertically” is meant perpendicularly to thehorizontal plane. By “up” is meant towards the front side and by “down”towards the rear side.

Known Technique and Problems Thereof

FIG. 1 shows a known embodiment of the new “paper free” floor type witha solid surface 5 comprising a mixture of fibres, preferably wood fibres14, small hard wear resistant particles 12, 12′ and a binder 19. Thewood fibres are generally unrefined and of the same type as used in HDFand particleboard. They comprise natural resins such as lignin. The wearresistant particles (12,12′) are preferably aluminium oxide particles.The surface layer comprises preferably also colour pigments 15 or otherdecorative materials or chemicals.

A preferable binder is melamine or urea formaldehyde resin. Any otherbinder, preferably synthetic thermosetting resins, could be used. Thesolid layer 5 is generally applied in dry powder form on a wood basedcore 6, such as for example HDF, and cured under heat and pressure. Thebinder 19 penetrates into the upper part of the core 34 and connects thesolid surface layer to the core.

An advanced decorative pattern can be applied in line on a scattered orpre-pressed surface with for example an ink jet digital device, whichallows the ink to penetrate into the powder. The major disadvantage isthat printing is made before pressing and special positioning isrequired if the printed pattern should be coordinated with the embossedstructure created by the press plate

An integrated pressing and design “stamp” method can be used whereby anembossed pressure matrix comprising protrusions, which are covered witha selected paint, for example with a rubber roller that applies thepaint only on the protrusions and not on the matrix parts located atlower portions between the protrusions. During pressing, it is possibleto apply the selected paint only in the sections of the surface that arepressed below the top parts of the surface layer and a perfectcoordinated design and structure could be obtained. The maindisadvantage is that ink has to be applied on the hot press plate andthat a roller must be inserted into the press. This will have a negativeimpact on the pressing capacity.

OBJECTS AND SUMMARY

An overall objective of embodiments of the disclosure is to provide abuilding panel, preferably a floor panel with a solid surface, which hasbetter design properties and/or cost structure than the known buildingpanels.

A first objective of embodiments of the disclosure is to provide a solidlaminate panel, preferably a floor panel, with an advanced surfacedesign preferably coordinated with an embossed structure, which can becombined with a high wear resistance.

A second objective of embodiments of the disclosure is to provide a costefficient method to produce advanced surface design,

According to a first aspect of the disclosure a production method isprovided comprising the steps of:

-   -   Applying a layer comprising a mix of fibres, binder and wear        resistant particles, preferably aluminium oxide particles, on a        carrier.    -   Providing embossed portions on the layer by pressing the mix        with an embossed matrix.    -   Filling the embossed portions with decorative material.

The pressing can be made as a pre pressing before the main pressingwhich cures the surface under heat and pressure. The decorative materialis in this alternative applied after the pre pressing but before themain pressing. The advantage is that even a glossy flat surface can bemade with the decorative material incorporated into the solid laminatesurface. The pre pressed surface could of course also be pressed with anembossed matrix in the main pressing step.

The decorative material can also be applied after the main pressingstep. In such a case an embossed structure can be maintained.

The two principles can be combined and several pressing steps can bemade for example pre pressing, main pressing and secondary pressing anddecorative materials can be applied before and/or during and/or afterthe main and/or secondary pressing steps.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will in the following be described in connection topreferred embodiments and in greater detail with reference to theappended exemplary drawings, wherein

FIG. 1 illustrates a known solid laminate surface;

FIGS. 2 a-d illustrate a method to form a decorative surface;

FIGS. 3 a-c illustrate an alternative method to form a decorativesurface;

DETAILED DESCRIPTION OF EMBODIMENTS

FIGS. 2 a-2 d show a production method to produce a decorative surface 5in order to form a building panel 1 according to the invention. A mix 5of fibres, binder, and wear resistant particles is applied on a carrier6, which preferably is a wood based core as shown in FIG. 2 a. The mixis preferably applied with scattering equipment in dry form and couldpreferably comprise a decorative substance, for example colour pigmentsthat provide a basic colour.

An embossed portion 4 is formed by pre pressing in the uncured surfacemix 5 with a matrix 2 a as shown in FIG. 2 b. A decorative substance 3is applied in the embossed portion (FIG. 2 c) and the surface is pressedin a main pressing step where the mix 5 is cured to its final form, asshown in FIG. 2 d.

The decorative substance can be applied in many ways for example byapplications where scattering is combined with vibration and where thedecorative substance is automatically positioned in the embossedportions. The decorative substance can also be applied as a layer thatpartly or completely covers the surface after excess material outsidethe embossed portions is removed for example mechanically or withcompressed air and similar methods.

Suitable decorative substances are colour pigments, paint, ink, pastesand pre coloured fibres.

The decorative substance comprises preferably also wear resistantparticles and binders.

FIGS. 3 a-3 c show an alternative method according to the invention. Thesurface 5 is applied as powder (FIG. 3 a) and pressed in a main pressingstep such that embossed portions 4 are formed in the cured surface.

The embossed portions are filled with a decorative substance that canfill the whole embossed portion or only parts such that a perfectcoordination between the design and embossing is obtained.

The decorative material can be cured with various known methods after orduring the application into the embossed portions. Further pressingsteps are not excluded.

Using a paper based overlay or an overlay which is applied in wet or dryform and which comprised wear resistant particles, is not excluded andthis could increase the wear resistance.

1. A method of manufacturing a building panel comprising the steps of:applying a layer comprising a mix of fibres, binder, and wear resistantparticles on a carrier; pressing the layer with an embossed matrix andproviding embossed portions; and after pressing, and in a separate step,filling the embossed portions with a decorative substance.
 2. The methodas claimed in claim 1, wherein the panel is a floor panel.
 3. The methodas claimed in claim 1, the step further comprising an additionalpressing that is made after filling of the embossed portions.
 4. Themethod as claimed in claim 1, wherein the carrier is a HDF board.
 5. Themethod as claimed in claim 1, wherein the decorative substance compriseswear resistant particles and a binder.
 6. The method as claimed in claim1, wherein the decorative substance comprises colour pigments and woodfibres.
 7. The method as claimed in claim 2, wherein the carrier is aHDF board.
 8. The method as claimed in claim 3, wherein the carrier is aHDF board.
 9. The method as claimed in claim 5, wherein the wearresistant particles of the decorative substance are aluminium oxideparticles.
 10. The method as claimed in claim 2, where the decorativesubstance comprises wear resistant particles.
 11. The method as claimedin claim 10, wherein the wear resistant particles of the decorativesubstance are aluminium oxide particles.
 12. The method as claimed inclaim 3, where the decorative substance comprises wear resistantparticles.
 13. The method as claimed in claim 12, wherein the wearresistant particles of the decorative substance are aluminium oxideparticles.
 14. The method as claimed in claim 4, where the decorativesubstance comprises wear resistant particles.
 15. The method as claimedin claim 14, wherein the wear resistant particles of the decorativesubstance are aluminium oxide particles.
 16. The method as claimed inclaim 1, wherein the wear resistant particles are aluminium oxideparticles.
 17. A method of manufacturing a building panel comprising thesteps of: applying a layer comprising a mix of fibres, binder, and wearresistant particles on a carrier; pressing the layer with an embossedmatrix and providing an embossed portion; and filling the entirety ofthe volume of the embossed portion with a decorative substance.
 18. Amethod of manufacturing a building panel comprising the steps of:applying a layer comprising a mix of fibres, binder, and wear resistantparticles on a carrier; pre-pressing the layer with an embossed matrixand providing embossed portions; filling the embossed portions with adecorative substance; and curing the layer under heat and pressure. 19.The method of claim 18, wherein the filling step comprises filling theentirety of the volume of the embossed portion with a decorativesubstance.
 20. The method of claim 19, wherein the cured layer is flatacross the embossed portion.
 21. A method of manufacturing a buildingpanel comprising the steps of: applying a layer comprising a mix offibres, binder, and wear resistant particles on a carrier; pressing thelayer with an embossed matrix and providing embossed portions; andfilling the embossed portions with a powdered colour pigment in a dryform.
 22. A method of manufacturing a building panel comprising thesteps of: applying a layer comprising a mix of fibres, binder, and wearresistant particles on a carrier; pressing the layer with an embossedmatrix and providing embossed portions; and filling the embossedportions with a decorative substance, by applying the decorativesubstance by scattering combined with vibration.
 23. The method asclaimed in claim 1, where the decorative substance comprises wearresistant particles.
 24. The method as claimed in claim 23, wherein thedecorative substance further comprises a color pigment.
 25. The methodas claimed in claim 17, where the decorative substance comprises wearresistant particles.
 26. The method as claimed in claim 18, where thedecorative substance comprises wear resistant particles.
 27. The methodas claimed in claim 21, where the decorative substance comprises wearresistant particles.
 28. The method as claimed in claim 22, where thedecorative substance comprises wear resistant particles.